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NUMBER: 1–SECM–03 S.M. REF.

: Listed in Table 1 ENGINE: ALL DATE: February 2003

SUBJECT: UPDATES FOR TROUBLESHOOTING SERIES 60 AND SERIES 50 EGR RELATED


CODES AND FAULTS

INTRODUCTION
The Series 60® engine for 2002/2003 includes EGR (Exhaust Gas Recirculation) technology. The use
of EGR was developed on the Series 50® engine two years ago, and with some enhancements is now
released on Series 50 and Series 60 on-highway engines.

DETAILS AND REASON


This bulletin is intended to provide troubleshooting of the DDEC related components used in the EGR
system.
The attachments to this SIB are designed to fit properly within the current DDEC Single ECM manual,
and in most instances are full sections to make insert of the material into the manual easy. For that
reason, change bars are not on the new material, but a revision date is entered in the footer.
Attachments include the following; listed in Table 1:
Section
Title Reference
Number
02 Operations Refer to section 2.
03 ECM and Sensor Locations Refer to section 3.
04 Basic Knowledge Required Refer to section 4.
05 Flash Codes vs SAE Codes Refer to section 5.
10 TOC Intermittent Fault Refer to section 10.
10 Intermittent Fault; 10.16; 10.17; 10.18 Refer to section 10.16 - 10.18.
17 Flash Code 17 – Throttle Valve High: Relative Refer to section 17.
Humidity Sensor High
18 Flash Code 18 - Throttle Valve Low; Relative Refer to section 18.
Humidity Sensor Low
29 Flash Code 29 – TCI / TCO Temperature Low Refer to section 29.
33 Flash Code 33 - TBS High Refer to section 33.
34 Flash Code 34 - TBS Low Refer to section 34.
39 Flash Code 39 – EGR Valve / VNT Vane Fault Refer to section 39.
48 Flash Code 48 - Air / Fuel / EGR Pressure Low Refer to section 48.
or EGR / TCI / TCO Temperature Low
49 Flash Code 49 – TCO or TCI Temperature High Refer to section 49.
51 Flash Code 51 – TCO or TCI Temperature Refer to section 51.
Circuit Failed High
55 Flash Code 55 - J1939 Data Link Fault Refer to section 55.
77 Flash Code 77 - Exhaust Back Pressure Fault Refer to section 77.
and several Information Codes
78 Flash Code 78 — Cruise Control / Adaptive Refer to section 78.
Cruise control
81 Flash Code 81 – Oil Level, Exhaust Temp, EGR Refer to section 81.
Temp or EGR Delta-Pressure, Circuit Failed
High
82 Flash Code 82 – Oil Level, Exhaust Temp, EGR Refer to section 82.
Temp or EGR Delta-Pressure, Circuit Failed
Low
83 Flash Code 83 – EGR Temp, EGR Refer to section 83.
Delta-Pressure, Exhaust Temp, or External
Pump Pressure High
92 TOC Engine Wiring Schematics For TOC, refer to section 92.
Section
Title Reference
Number
92 Engine Wiring Schematics Refer to section 92 for 92.8 and 92.9.
93 TOC Vehicle Wiring Schematics For TOC, refer to section 93.
93 Vehicle Wiring Schematics Refer to section 93 for 93.8 and 93.9.

Table 1 Sections Updated


Troubleshooting all EGR related complaints will start with section 10.16 for Series 50 engine and section
10.18 for Series 60 engines.
New engine models designate the Series 60 is built with EGR technology; these models are listed in
Table 2.
Engine Models Description
6067MK2E 12L Coach
6067HK2E 14L Coach
6067MK4E 12L Fire Truck
6067HK4E 14L Fire Truck
6067MK6E 12L Truck
6067HK6E 14L Truck

Table 2 EGR Technology


The components used in today’s Series 60 engines will also be applied to the Series 50 engines for 2003.
These enhancements include:
EGR Cooler
VPOD (Variable Output Pressure Device)
Delta-P Sensor
EGR Temperature Sensor
Relative Humidity/Turbo Compressor Inlet (TCI) Temperature
All new engine sensors using improved connectors
Turbo Compressor Outlet (TCO) Temperature
SERVICE
Expanded information can be found in the DDEC IV A & I manual that can now be downloaded from
the DDC Extranet.
Standard DDEC tools are still required.
To properly diagnose an EGR engine, the following tools are needed:
1000 ohm resistor
Pressure gages (0–200 psi)
DDR with suite 8 minimum
DDDL version 4.2 or higher
Terminals and Connectors
Connector kits are available individually or in a kit P/N 23527566.
Listed in Table 3 is the breakdown of this kit.
P/N Description
23528256 SRS
23528257 TRS
23528258 Oil Pressure
23528259 Turbo Boost Pressure
23528260 Barometric Pressure
23528261 Intake Air Temp
23528262 Oil Temp
23528263 Coolant Temp
23528265 EGR Temp
23528266 Fuel Temp
23528267 Relative Humidity/TCI
23528268 OEM (Harness side)
23528269 Turbo Compressor Temp
23528279 EGR Delta-Pressure
23530463 OEM (Vehicle side)
23530464 VPOD/12v — FCI connector (DDEC IV 2002 only)
23530465 VPOD/24v — Ampconnector (DDEC IV 2002 only)
23530468 Turbo Speed (DDEC IV 2002 only)

Table 3 Connector Kits

ADDITIONAL SERVICE INFORMATION


Additional service information is available in the Detroit Diesel DDEC III/IV Single ECM
Troubleshooting Guide, 6SE497. The next revision to this guide will include the revised information.
As a convenience to holders of the DDEC III/IV Single ECM Troubleshooting Guide, information in
troubleshooting guide format is attached. The page(s) may be inserted into the guide.
NOTE:
Manual insert pages are numbered for insertion into the current DDEC III/IV Single ECM
Troubleshooting Guide dated July 2002. Troubleshooting guides are available from authorized Detroit
Diesel distributors. If this bulletin was obtained from the Internet, troubleshooting guide page(s) are
available by returning to the screen “SIB Index”, selecting attachment pages, and printing the page(s).

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